HYDRAULIC RESCUE EQUIPMENT

Transcription

1 Operating instructions HYDRAULIC RESCUE EQUIPMENT Battery powered devices Mains adapter Tested according to EN and NFPA 1936 Hydraulic rescue equipment (rechargeable devices): Page 1/40

2 Table of Contents 1 General Information regarding the operating instructions Explanation of symbols Limitations of liability Copyright Guarantee conditions Customer service 7 2 Safety Appropriate use Responsibility of the customer Operating personnel Personal protective gear Specific hazards Safety devices Behaviour in the event of danger or accidents Signage 17 3 Technical data Operating conditions Type plate 20 4 Structure and function Overview Brief description Hydraulic supply Connection to the energy pack Use of the control handle Changing the spreader jaws (SP 35 A and SPS 330 A) Accessories (SP 35 A and SPS 330 A) 24 5 Energy pack Safety information General Control and charging electronics Hanging / wearing Charging Mains adapter Accessories 28 6 Possible applications Safety information Cutting (S 180 A and SPS 330 A) Spreading (SP 35 A and SPS 330 A) Pulling (SP 35 A and SPS 330 A) Crushing (SP 35 A and SPS 330 A) Lifting (SP 35 A and SPS 330 A) 32 Hydraulic rescue equipment (rechargeable devices): Page 2/40

3 Table of Contents 7 Transport, packaging, and storage Safety information Transport inspection Symbols on the packaging Disposal of packaging Storage 34 8 Installation and commissioning Safety information Checks Installation Shutting down (end of work) 36 9 Servicing Safety information Care and maintenance Maintenance schedule Faults Decommissioning / recycling 40 Hydraulic rescue equipment (rechargeable devices): Page 3/40

4 General 1 General 1.1 Information regarding the operating instructions These operating instructions provide information for using the rechargeable battery-powered hydraulic rescue devices (one-man portable). Compliance with all of the safety and handling instructions specified is a prerequisite for safe work. Furthermore, adhere to the local accident prevention guidelines and general safety regulations for the region in which the devices are used. Personnel must carefully read this manual prior to starting all work! It is an inherent part of the product and must be kept in a place that is known and accessible to personnel at all times. This documentation contains information for operating your equipment, irrespective of the equipment type. For this reason you will also find explanations which do not refer directly to your equipment. All information, technical data, graphics and diagrams contained in these operating instructions are based on the most up-to-date data available at the time of writing. Alongside the careful reading of the operating instructions we also recommend that you be trained and instructed on handling the rescue equipment (possible applications, application tactics etc.) by our qualified trainers. Hydraulic rescue equipment (rechargeable devices): Page 4/40

5 General 1.2 Explanation of symbols Warning instructions Warning instructions are marked by symbols in this operating manual. The individual instructions are introduced by signal words that express the extent of the hazard. It is essential to comply with the instructions in order to prevent accidents, injuries and damage to property. DANGER!... indicates an immediate dangerous situation that can result in death or serious injury if it is not avoided. WARNING!... indicates a potentially dangerous situation that can result in death or serious injury if it is not avoided. CAUTION!... indicates a potentially dangerous situation that can result in minor or light injuries if it is not avoided. ATTENTION!... indicates a potentially dangerous situation that can result in material damage if it is not avoided. Tips and recommendations NOTE!... indicates useful tips and recommendations as well as information for efficient and trouble-free operation. Hydraulic rescue equipment (rechargeable devices): Page 5/40

6 General 1.3 Limitations of liability All information and instructions in this operating manual have been provided under due consideration of applicable standards and guidelines, the current state of technology, as well as our many years of knowledge and experience. The manufacturer assumes no liability for damage due to: Disregard of the operating instructions Improper use Deployment of untrained personnel Unauthorized conversions Technical changes Use of non-approved spare parts Use of non-original spare parts The actual scope of delivery can vary from the explanations and graphic representations provided in this manual in the case of special versions, or due to technical changes. 1.4 Copyright All text, diagrams, drawings and images in this operating manual may be used without restriction and without any prior approval. NOTE! Further information, images and drawings can be found on our homepage. Hydraulic rescue equipment (rechargeable devices): Page 6/40

7 General 1.5 Guarantee conditions The guarantee conditions can be found as a separate document in the sales documentation. 1.6 Customer service Our customer service department is available to you for technical information. Germany Name: Ms. Corina Schulz Telephone: +49 (0) 7135 / Fax: +49 (0) 7135 / corina.schulz@weber.de Austria Name: Mr. Robert Niederhofer Telephone: +43 (0) 7255 / Fax: +43 (0) 7255 / robert.niederhofer@weber-hydraulik.at NOTE! When contacting our customer service department please provide the designation, type and year of manufacture of your equipment. This information can be found on the equipment type plate. Hydraulic rescue equipment (rechargeable devices): Page 7/40

8 Safety 2 Safety This section of the operating manual provides a comprehensive overview of all the important safety aspects for optimal protection of operating personnel, as well as for safe and trouble-free operation. Significant hazards can occur if the handling and safety instructions in this manual are not complied with. 2.1 Appropriate use The rechargeable hydraulic devices are designed and tested exclusively for the appropriate designated purposes described here. All other activities are fundamentally prohibited. Rechargeable devices () All of the rechargeable devices are designed as one-man devices and may thus be operated by one person only. The S 180 A serves exclusively for the cutting of doors and roof pillars, posts and sills, the rims and spokes of steering wheels. The rear cutter section should be used whenever possible for separating solid material as this is equipped with special round material cutters. In industrial applications the equipment can also be used for cutting pipes, construction steel, profiles, sheets and cables. The SP 35 A serves exclusively for the opening of doors, the lifting of vehicles or other moveable loads, the pushing away and moving of vehicle parts and loads and the crushing of tubes and pillars. The spreader jaws should be used whenever possible for crushing. The spreader jaws can be used as a peeling tool. The chain set is to be used exclusively for pulling. The combination device SPS 330 A may be used for the same purposes as those specified for the S 180 A and the SP 35 A. Hydraulic rescue equipment (rechargeable devices): Page 8/40

9 Safety Accessories (, carrier) The energy pack serves exclusively for operating the WEBER- HYDRAULIK rechargeable devices and may only be charged with the original mains adapter. The mains adapter and the carrier are designed and approved only for the WEBER-HYDRAULIK energy pack. The RZM 700 may only be used in conjunction with SPS 330 A. It serves exclusively to push steering columns, vehicle roofs and other obstacles upwards and to push vehicle parts out of the way. In addition, it can be used to brace, stiffen and pull. WARNING! Danger due to improper use! Any use of the equipment that exceeds the intended use or deviates from it can lead to dangerous situations! Therefore it is imperative that: - The equipment is used only for the purposes listed above. - Observe all other instructions in chapter 5 (possible applications) regarding appropriate use of the equipment. Hydraulic rescue equipment (rechargeable devices): Page 9/40

10 Safety 2.2 Responsibility of the customer In addition to the working safety instructions in this operating manual, observe safety and accident protection guidelines and environmental protection guidelines applicable to the area of application of the equipment. Particularly applicable in this regard: The customer must inform himself of applicable industrial safety regulations, and in a hazard analysis identify other hazards that may exist at the equipment's installation site due to the special working conditions. The customer must clearly regulate and specify responsibilities for installation, operation, maintenance, and cleaning. The customer must ensure that all personnel who handle the equipment have fully read and understood the operating manual. In addition, the operator must train personnel and inform them of the dangers of working with the machinery at regular intervals. Moreover, the customer is responsible for ensuring that the equipment is always in technically faultless condition. Consequently the following applies: After every usage, at least once per year, the device must undergo a visual inspection by trained personnel (per GUV-G 9102 or country-specific directive). Every three years, or in the event of doubts about the safety or reliability of the equipment, an additional functional and load test is to be carried out (per GUV-G 9102 or country-specific directive). Hydraulic rescue equipment (rechargeable devices): Page 10/40

11 Safety 2.3 Operating personnel The following qualifications are cited in the operating manual for the various activity areas: Trained person Is informed about the tasks assigned to them and the possible dangers in the event of improper behaviour through customer training. Specialist Is an individual who, due to their specialized training, skills, and experience, as well as knowledge of the applicable manufacturer's regulations is capable of executing the tasks assigned to them and of recognizing possible hazards on their own. WARNING! Danger of injury due to insufficient training! Improper handling of the equipment can lead to serious injury or material damage. Therefore it is imperative that: - Particular tasks are only carried out by the personnel listed in the appropriate chapter of this instruction manual. - In case of doubt call in specialists immediately. NOTE! The equipment may not be used by personnel who have consumed alcohol, taken medication or drugs! Hydraulic rescue equipment (rechargeable devices): Page 11/40

12 Safety 2.4 Personal protective gear Wearing personal protective equipment (PPE) is essential to minimize the risks to operating personnel when working with the rechargeable hydraulic devices. It is essential to wear the following protective clothing for all work: Protective work clothing Tight-fitting work clothing with tight sleeves and without projecting parts should be worn for work. It is primarily used to protect against entanglement by moving equipment parts. Safety footwear Safety footwear with steel toecaps must always be worn as protection against heavy falling parts and from slipping on slippery ground. Work gloves Work gloves must be worn when working with the equipment for protection against sharp edges and glass fragments. Helmet with face shield A helmet with face shield must be worn for protection against flying or falling parts and glass fragments. Protective goggles Protective goggles must also be worn in addition to the face shield in order to protect the eyes from slivers. With certain work the following must also be worn in addition: Ear protectors In addition to the basic protective equipment, ear protectors should also be worn for protection against hearing damage. Hydraulic rescue equipment (rechargeable devices): Page 12/40

13 Safety 2.5 Specific hazards The hazards that arose within the framework of the risk evaluation are listed in the following section. Follow the safety instructions listed here and the warning instructions in the other sections of this manual to minimise potential health hazards and avoid dangerous situations. Electric shock DANGER! Life-threatening danger due to electric shock! There is an imminent life-threatening danger if live parts are touched. Damage to insulation or to specific components can pose a life-threatening danger. Therefore: - Disconnect the power supply immediately if there is damage to the insulation and have it repaired. - Only a qualified electrician should perform work on the electrical equipment. - All electrical work on the system must be carried out with the system disconnected from the mains power supply and the system must be check to confirm that it is de-energised. - Prior to any maintenance, cleaning or repair works the power supply must be switched off and secured against being unintentionally switched back on. - Do not bypass fuses or render them inoperable. Always use the correct amperage when changing fuses. - Keep moisture away from live parts. Moisture can lead to a short circuit. Hydraulic rescue equipment (rechargeable devices): Page 13/40

14 Safety Noise WARNING! Hearing damage due to noise! The noise occurring in the work area can cause severe hearing damage. Therefore: - Also wear ear protectors when carrying out particularly noise-intensive works. - Do not stay in the hazardous area longer than necessary. Hydraulic energy WARNING! Danger due to hydraulic energy! Serious injuries can be caused by discharged hydraulic force and the emergence of hydraulic oil. Therefore: - Always keep your eyes on the hydraulic equipment throughout the working process and set down if necessary. - Check the hose lines and the equipment for damage after every usage. - Avoid skin contact with the hydraulic oil (wear protective gloves). - Remove hydraulic oil from wounds without delay and seek medical attention immediately. Hydraulic rescue equipment (rechargeable devices): Page 14/40

15 Safety 2.7 Behaviour in the event of danger or accidents Preventative measures Always be prepared for accidents Keep first aid equipment (first-aid box, blankets etc.) to hand Familiarize personnel with accident alarms, first-aid kits, and rescue equipment Keep entry ways clear for rescue vehicles In the event of an accident Shut down the equipment immediately Initiate first-aid measures Get people out of the danger zone Inform the responsible parties at the implementation site Notify a physician and/or the fire department Keep entry ways clear for rescue vehicles Hydraulic rescue equipment (rechargeable devices): Page 15/40

16 Safety 2.8 Signage The following symbols and instruction signs are found on the equipment. These symbols and instructions refer to the immediate vicinity in which they are affixed. Comply with the instructions in the operating manual Do not use the marked equipment until after you have read the operating manual. Warning of injury to hands When working with the equipment care should be taken to avoid hand injuries through clamping or sharp edges. WARNING! Danger of injury due to illegible symbols! Over time, stickers and symbols on the equipment can be become fouled or can become illegible in some other manner. Therefore it is imperative that: - Keep all safety, warning, and operating instructions that are affixed to the device in good, legible condition. - Replace damaged signs and stickers immediately. Hydraulic rescue equipment (rechargeable devices): Page 16/40

17 Technical data 3 Technical data S 180 A SP 35 A SPS 330 A Energy pack Mains adapter (M-M 230 V) S 180 A SP 35 A SPS 330 A Length 791 mm 886 mm 840 mm Width 222 mm 215 mm 222 mm Height 192 mm 208 mm 191 mm Weight 18.7 kg 23.0 kg 17.4 kg Opening width 180 mm 620 mm 330 mm Max. cutting force 42 t - 24 t Max. cutting capacity with round material Ø 30 mm - Ø 25 mm Spreading force in working range kn kn Clamping force - 99 kn 35 kn Spreading distance mm 330 mm Pulling distance mm 400 mm Pressure 700 bar 700 bar 700 bar DIN class C150-G-E S30-E K25-F-E Part no Hydraulic rescue equipment (rechargeable devices): Page 17/40

18 Technical data Length Width Height Weight 219 mm 85 mm 279 mm 8.5 kg Energy pack Rated voltage 12V DC (direct current) Nominal capacity 20 Ah Type of protection IP 54 Input voltage range V DC (direct current) Max. input current 17 A at 12V; 8.5 A at 24V Nominal charging current 7 A Charging voltage / Nominal output voltage 14 V-DC (direct current ) Charging as per DIN Temperature range when charging + 5 to + 35 C Operating temperature - 20 C to + 60 C Part no Length Width Height Weight 158 mm 110 mm 40 mm 0.9 kg Mains adapter Input voltage 230 V AC (alternating current), 50 Hz max. 200 VA Nominal output voltage 14 V-DC (direct current ) Nominal charging current 7 A-DC (direct current ) Charging as per DIN Temperature range (operating) - 20 C to + 50 C Relative humidity up to 80% Type of protection SKI / IP 20 Part no Hydraulic rescue equipment (rechargeable devices): Page 18/40

19 Technical data 3.1 Operating conditions The permissible operating temperature range for the rechargeable equipment is - 20 C to + 60 C. Reliable functioning of the equipment cannot be guaranteed outside this range. 3.2 Type plate The type plate can be found on the device body of all cutting devices. Here you can find the serial number, manufacturing date, nominal pressure, equipment designation and the EN standard. Hydraulic rescue equipment (rechargeable devices): Page 19/40

20 Design and Function 4 Structure and function of the equipment 4.1 Overview 1 Cutter (arms) 2 Protective cover 3 Handle 4 Bayonet connector 5 Rocker lever 6 Device body 7 Pump unit 8 Electrical power cable 4.2 Brief description Rechargeable hydraulic devices are specially designed rescue equipment for cutting or spreading bodywork parts. They are used for rescuing trapped or enclosed accident victims. They are not tied to a vehicle because they have their own internal electrohydraulic drive, and so can also be used in inaccessible places. The speed of movement of the shearing blades is controlled by the greater or lesser degree of force applied to the rocker lever on the handle. The maximum force is only applied when the rocker lever is actuated to its fullest extent. Hydraulic rescue equipment (rechargeable devices): Page 20/40

21 Design and Function 4.3 Hydraulic supply Drive The drive of the rechargeable device is created through a permanently exited 12V DC motor with a nominal power of 400 Watts. The drive motor runs only as long as the rocker switch is being actuated. Pump The hydraulic pressure is created by a high pressure hydraulic pump (in the pump unit). The pump is a swashplate axial piston pump with four pistons. The pressure acts directly on the working cylinder and so there is no need for connection lines in the equipment. Oil tank The volume of oil for operation is taken from a spring-loaded piston-type accumulator. The complete hydraulic system is therefore completely closed and void of air. The system pressure (accumulator pressure) is 0.5 bar. Any possible reduction in volume as a result of heat will be balanced out by the accumulator. Hydraulic oil All rechargeable devices are designed and tested for AERO Shell Fluid 41 hydraulic oil. This oil possesses a particularly high purity level and also works flawlessly at temperatures below zero, down to -20 C. The oil does not usually require changing, however if this should become necessary then an oil change must be performed by WEBER HYDRAULIK service personnel only. Hydraulic rescue equipment (rechargeable devices): Page 21/40

22 Design and Function 4.4 Connections to the energy pack To connect the equipment to the energy pack, the bayonet connector must first be gently inserted into the coupling half on the energy pack. Fasten the bayonet connection by tightening clockwise. Ensure that the lock engages correctly at this time. 4.5 Use of the control handle The rechargeable device can be operated by the rocker lever on the control handle. The speed of movement of the shearing blades/arms is controlled precisely by the greater or lesser degree of force applied. The maximum cutting or spreading force is only applied when the rocker lever is actuated to its fullest extent. Close cutters / open spreaders The primary motion of the device is triggered by moving the rocker lever to the left. Open cutters / close spreaders The cutters are opened or the spreaders closed by moving the rocker lever to the right. Dead-man's switching If the rocker lever is released then it returns to the neutral position automatically. With this, the device stops still in any position (including under load). Symbol to close: Symbol to open: Hydraulic rescue equipment (rechargeable devices): Page 22/40

23 Design and Function 4.6 Changing the spreader jaws (SP 35 A and SPS 330 A) The spreader jaws are secured with collar studs in the spreader arms. In order to change, press out the studs secured by a spring-loaded ball. After changing the jaws, push the collar studs back in again. When doing this ensure that the studs are correctly seated (completely pressed in). Fitting the bracket for the chain set is identical. The chain master link must be fitted with the lock facing upwards. NOTE! In order to fit the chain master link onto the SPS 330 A, two additional pulling adapters are necessary - they must be fitted first (same system as for the spreader jaws). 4.7 Accessories (SP 35 A and SPS 330 A) Chain set A chain set is required in order to be able to pull with the SP 35 A or the SPS 330 A. The two chain master links and the hooks are included. Order number: Pulling adapter To attach the chain set to the SPS 330 A, two pulling adapters are required in addition to the chain master link. Order number: Rescue cylinder RZM 700 A rescue cylinder attachment is available with which to increase the spreading distance of the SPS 330 A to 700 mm. This is attached to the jaws by means of ball studs. Order number: Hydraulic rescue equipment (rechargeable devices): Page 23/40

24 Energy pack 5 Energy pack 5.1 Safety information 5.2 General CAUTION! Once the equipment connector is inserted the rechargeable device is immediately ready for operation. Therefore, always pull out the connector when not in use in order to prevent accidents. The energy pack comprises a rechargeable, leak-proof and storage-tolerant lead acid battery (12V / 20A), a control unit with acoustic warning device and an integrated charging device for 12V 32V DC. The battery comprises an encapsulated, maintenance-free, lead acid storage battery with highly absorbent separators (webbing inserts). This can be charged either by the integrated charger or via a separate mains charger (230V AC). The service life of the battery is specified by the manufacturer as five years or 1,000 charging cycles. A test and reset button, four LEDs, a screw locking device, the charging socket (switchable to consumer) and an interconnection terminal for remote operation of the Hydro-Pac are located on the top side. A consumer such as a hand-held spotlight up to 100 W can be connected to the charging socket (changeover via the rocker switch). Attention! The deep discharge protection (chapter 5.3) is disabled by this! NOTE! The energy pack battery is approved for transport in aircraft by the IATA (International Air Transport Association). Hydraulic rescue equipment (rechargeable devices): Page 24/40

25 Energy pack 5.3 Control and charging electronics The control electronics have the task of ensuring that the rescue device is always ready for use through switching functions and monitoring functions. The monitoring is carried out by a microprocessor that is integrated in the splash-proof glued plastic housing of the energy pack together with the control and charging electronics. Monitoring electronics The monitoring electronics enable a check of the charge status of the energy pack whilst in idle state using the "Test" pushbutton and with a test resistor. The result is displayed via a row of LEDs (red, yellow, green). GREEN: Battery fully charged GREEN/YELLOW: Battery slightly discharged YELLOW: Battery is half discharged YELLOW/RED: Battery is substantially discharged RED: Battery is almost completely discharged! Deep discharge protection (DDP) When starting up a device, permanent voltage monitoring starts automatically. If due to use, the factory set threshold voltage of 10.5V is undercut, an acoustic signal (peeping) sounds after a three second delay and the red "ALARM" LED illuminates. If the threshold voltage of 8.5V is also undercut through further use then after another three second delay the battery will be disconnected from the device in order to avoid the battery being damaged. This forced shut-down is signalled by a constant tone and also this remains intact (self-latching) after the device is switched off. The forced shut-down can be alleviated briefly by pressing the RESET button in order to be able to drive the device back to its default position, or if necessary to carry out a few final actions. ATTENTION! The energy pack may be reset a maximum of three times! If it used more frequently without the device being recharged in the meantime, this can lead to serious damage to the battery and the motor of the rescue device. Hydraulic rescue equipment (rechargeable devices): Page 25/40

26 Energy pack Charging electronics The battery is charged by an integrated electronically-controlled charging device. The charge status of the battery is irrelevant to this. It is also unnecessary to completely discharge the battery before recharging because lead acid batteries do not exhibit a memory effect. Overcharging the battery is prevented by a voltage limiter in the charger. 5.4 Hanging / wearing The energy pack should be worn on the left side with the upper edge at belt height if possible. Worn in this way, the receptacle for the equipment connector points rearwards and the connection cable runs behind the feet, meaning that it does not hang as an obstruction. The shoulder strap is drawn over the head and placed on the right shoulder so that it can not slide off the shoulder whilst working. The harness is equipped with a quick-release fastener in the middle. It is pulled at tight at both loose ends so that the energy pack rests close to the body. Alternatively, the energy pack can also be worn on the back. Two shoulder straps are used for this, each of which is hooked through the eyelet. Thus, the energy pack can be worn like a rucksack. (Order number for a second shoulder strap: ) 5.5 Charging The energy pack is charged via the charging cable ( ) directly connected to a 12-24V socket, or via the mains adapter ( ) connected to 230V / 50 Hz AC. When connecting, ensure that the connector is plugged into the energy pack before the charging cable is connected to a power source. In addition, make sure that the connector is well seated. When disconnecting, always disconnect the connector from the power source first and only then disconnect the energy pack. Otherwise there is a risk of a short-circuit. When charging correctly, the LEDs corresponding to the charge status of the battery flash. The green LED is continuously illuminated when the battery is fully charged or when it is being trickle-charged. The battery will only be deep discharged when the deep discharge protection (DDP) is switched off repeatedly by pressing of the RESET button. (Charging with reduced charge current - trickle charging) Hydraulic rescue equipment (rechargeable devices): Page 26/40

27 Energy pack 5.6 Mains adapter The following safety instructions must be followed when using the mains adapter to charge the energy pack: The mains adapter may not be used if there is known to be damage to the mains adapter or to the connection cable. Only run the mains adapter from earthed mains sockets. Do not expose the device to rain or water (use only in closed buildings). Ensure that liquid ingress to the mains adapter is prevented in all instances. CAUTION! Life-threatening voltage! Only plug and unplug the connection cable by the plug itself. Do not place objects on the mains adapter. Never cover or modify the device. WARNING! Improper charging can cause the formation of combustible gases in the energy pack batteries. Therefore: - Avoid flames and sparks when charging. - Only charge in well ventilated spaces. - Switch the mains adaptor off before unplugging the charging cable from the energy pack. 5.7 Accessories Mounting A mounting bracket is available for secure installation in a vehicle. This also enables charging from the vehicle power supply. Order number: Shoulder strap A second shoulder strap is required in order to wear the energy pack as a rucksack (chapter 5.4). Order number: Hydraulic rescue equipment (rechargeable devices): Page 27/40

28 Possible fields of application 6 Possible applications 6.1 Safety information WARNING! Never reach between the cutter arms! WARNING! During all work with the rechargeable devices, parts which are tensioned can break off or be blown off and thus endanger personnel. Therefore, personnel who are not directly involved must maintain a safe distance or only stay in the hazardous area as long as is strictly necessary. 6.2 Cutting (S 180 A and SPS 330 A) The cutting capacity of the equipment can only be optimally utilised if it is applied as close to the pivot point of the cutter as possible (Fig.1). Some readjustment of the equipment may be necessary here. The full cutting capacity of the device is only attained when the operating lever is fully depressed. In addition, there can be a delay of a few seconds before the unit has full working pressure available. Fig. 1 Hydraulic rescue equipment (rechargeable devices): Page 28/40

29 Possible applications In order to avoid the cutter being damaged, it must always be applied at right angles to the cutting material. In addition, the shearing blades must not be more than 5 mm apart at the tips during the cutting process. If this value is exceeded then the cutting process must be aborted and the cutter reapplied. CAUTION! Do not cut parts with free ends as this poses a danger of personnel being injured by flying parts. ATTENTION! Cutting high strength body parts such as shock absorbers, hinges or steering columns must be avoided as this can cause serious damage to the shearing blades (arms). Hydraulic rescue equipment (rechargeable devices): Page 29/40

30 Possible applications 6.3 Spreading (SP 35 A and SPS 330 A) With the help of the rechargeable device's spreader function, possible applications include doors being opened or vehicle parts being pushed out of the way. A stable positioning and support of the vehicle is essential with this. In order to avoid slipping off when spreading, the arms and jaws are serrated on the inner and outer sides. It is best to spread using this area because the spreading force is highest here. In addition, slipping of can be avoided by readjusting the spreaders. If possible the tips should only be used to enlarge a gap. 6.4 Pulling (SP 35 A and SPS 330 A) After the chain set is attached to the spreader jaws (as explained in chapter 4.6), the rechargeable device can also be used for pulling. The chains must always be stretched taught during this application, and must only be loaded in the direction of pulling. To tension the chain, it is possible to press one lock in respectively so that the chain can be pulled through the bracket. If the pulling distance is insufficient then it must be secured with tensioning chains or alternative means so that the equipment can be opened again and the chain re-tensioned. ATTENTION! Please observe the separate operating instructions for the WEBER-HYDRAULIK chain set (ID ), so that the chain set is properly employed. Hydraulic rescue equipment (rechargeable devices): Page 30/40

31 Possible applications 6.5 Crushing (SP 35 A and SPS 330 A) The crushing of pipes and other hollow profiles is performed by closing the spreader arms. However, in the case of the SPS 330 A only the area of the tips can be used for crushing (fig. 2)! Fig. 1 Fig. 2 ATTENTION! Items being crushed can jump out suddenly. Do not remain in the working area of the spreader! 6.6 Lifting (SP 35 A and SPS 330 A) The rechargeable device can also be employed for lifting vehicles or other moveable loads. It is necessary to ensure that the load is secured against sliding away and that the spreader jaws are applied far enough under the load to prevent slippage. The lifting load must be observed constantly (for tilting, rolling away or changes in altitude) throughout the lifting process. In addition, the lifting load must be immediately supported and braced in an appropriate manner. Hydraulic rescue equipment (rechargeable devices): Page 31/40

32 Transport, packaging, and storage 7 Transport, packaging, and storage 7.1 Safety information CAUTION! Incorrect transportation can cause damage! Significant material damage can occur due to incorrect transportation. Therefore: - Proceed with caution when unloading packages and observe the symbols on the packaging. - Do not open fully or dispose of packaging until at the intended storage location. 7.2 Transport inspection The delivery should be checked immediately upon receipt for completeness and any possible transportation damage, so that a quick remedy can be instigated if necessary. In the event of visible external damage proceed as follows: Do not accept the delivery, or only accept it with reservation. Note the extent of transport damage on the transport documents or on the transport company's delivery note. Submit a complaint. NOTE! Report any defect as soon as it is detected. Claims for damages can be directed to our customer service department (see chapter 1.6). Hydraulic rescue equipment (rechargeable devices): Page 32/40

33 Transport, packaging, and storage 7.3 Symbols on the packaging Caution fragile! Handle the package carefully, do not drop, throw, strike or tie up. This way up! The package must be transported and stored strictly such that the arrows point upwards. Do not roll or tilt. 7.4 Disposal of packaging All packaging materials and disassembled parts (transportation protection) must be disposed of properly in accordance with applicable local regulations. 7.5 Storage The work equipment and the energy pack should be stored in a dry and dustfree environment where possible. In addition, the storage location should be cool but free of frost. It is possible to set the energy pack down outside whilst in use - even in the rain, but not in puddles. CAUTION! The equipment must be stowed securely in the mountings intended for this, in order to avoid it being damaged whilst in transit etc. Hydraulic rescue equipment (rechargeable devices): Page 33/40

34 Installation and commissioning 8 Installation and commissioning 8.1 Safety information WARNING! Danger of injury due to improper operation! Improper operation can cause serious injury or material damage. Therefore it is imperative that: - Execute all operating steps in accordance with the information in this operating manual. - Prior to starting work ensure that all covers and protective devices are installed and functioning properly. Personal protective gear Wear the protective gear detailed in chapter 2.4 with all work! NOTE! Special reference has been made where it is necessary to wear additional protective equipment for certain work with or on the device. 8.2 Checks Check the rechargeable device or the energy pack for damage. If the equipment should be found not to be in flawless condition then it must not be used! In this event, inform your supplier immediately. Check the cutter or arms (damage) Check the control handle including rocker lever (function) Check the bayonet coupling (damage, dirt) Check the hand grip (securely fastened) Check the protective cover (damage) Check the operating controls (function) Check the cable (damage) Hydraulic rescue equipment (rechargeable devices): Page 34/40

35 Installation and commissioning 8.3 Installation Prior to the first use it is necessary to completely charge the energy pack once. Following this, the work equipment can be connected. Once plugged in, the work equipment is immediately ready for operation. The energy pack does not need to be switched on first. 8.4 Shutting down (end of work) After the work is finished the cutter blades must be placed over each other or the spreader arms placed together, in order to preclude any risk of injury. The rechargeable device blades/arms must never be fully closed as this will cause hydraulic stress to be built up in the equipment. NOTE! With combination devices, drive the spreader arms to within a few millimetres of each other in order to relieve the hydraulics. Then the equipment can be disconnected from the energy pack. Hydraulic rescue equipment (rechargeable devices): Page 35/40

36 Servicing 9 Servicing 9.1 Safety information WARNING! Injury hazard due to improperly executed maintenance tasks! Improper maintenance can cause serious injury or material damage. Therefore it is imperative that: - Maintenance work is carried out only by specialist personnel. - Order and cleanliness are assured at the installation site! Parts and tools that are lying loose are a source of hazards. - Protective gloves are worn during all work! 9.2 Care and maintenance The following measures are imperative in the interest of maintaining a state of constant operational readiness: After each use and at least once per year, the device and the accessory parts must undergo a visual inspection. The spreader jaws, joints, blades, connection cable, housing and couplings in particular should be checked at this time. Recharge the energy pack immediately after every use. Every three years, or in the event of doubts about the safety or reliability of the equipment, an additional functional and load test is to be carried out (per GUV-G 9102 or country-specific directive). Fin grease OG must be injected into the moving parts and bolts from time to time. Hydraulic rescue equipment (rechargeable devices): Page 36/40

37 Servicing ATTENTION! The equipment must be cleaned of all contaminants before any maintenance work so that no dirt can enter the hydraulic system. The cleaning can be carried out with a standard citrus cleaning agent or with WD Maintenance schedule A more precise maintenance plan with test intervals, test regulations and test results can be taken from GUV - G 9102 item 17 (hydraulically actuated rescue equipment). NOTE! Our customer service department is available for you if there should be problems with the maintenance of the equipment (see chapter 1.6). Hydraulic rescue equipment (rechargeable devices): Page 37/40

38 Faults 10 Faults Fault Possible cause Remedial measures LEDs indicate a partial discharge although the energy pack is connected to a power supply. LEDs do not illuminate Mains adapter faulty Energy pack fuse (10A) faulty Equipment is not receiving power or is receiving too little power Check mains adapter and replace if necessary. Change fuse Check connection cable or mains adapter and replace if necessary Check power supply for sufficient voltage Damage to the housing of the mains adapter. Damage to the housing of the energy pack. Work equipment does not move - Send mains adapter to specialist dealer or manufacturer - Send energy pack to specialist dealer or manufacturer Connection cable not correctly coupled Energy pack not charged Couple connection cable properly. Charge energy pack Hydraulic rescue equipment (rechargeable devices): Page 38/40

39 Decommissioning / recycling 11 Decommissioning / recycling After the service life has expired the equipment must be disposed of correctly. Individual parts can however certainly be reused. The hydraulic oil must be completely drained off and collected. Please note that the hydraulic oil must be disposed of separately! The local disposal regulations apply to the disposal of all equipment parts and packaging materials. NOTE! Please consult your supplier regarding the disposal of the equipment. Hydraulic rescue equipment (rechargeable devices): Page 39/40

40 2009 edition, 2nd issue WEBER-HYDRAULIK GmbH Heilbronner Straße 30 Industriegebiet Güglingen/Germany 4460 Losenstein/Austria Tel.: +49 (0) 7135/ Tel.: +43 (0) 7255/ Fax: Hydraulic +49 rescue (0) 7135/ equipment (rechargeable devices): Fax: +43 (0) 7255/ Page 40/40 info@weber.de office@weber-hydraulik.at